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AssigneeEvolve Additive Solutions, Inc.
InventorsJ. Samuel Batchelder, Manish Boorugu, Andrew Rice
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Embodiments herein relate to 3D printing. In an embodiment, a method for printing an article using a selective toner electrophotographic process (“STEP”) includes successively depositing multiple layers of part material and support material, the layers deposited substantially parallel to a first plane; wherein: a) the multiple layers of part material and support material extend in a perpendicular to the first plane; and b) at least some of the layers of part material and support material are separated from each other to form a gap between the layers of part material and layers of support material; application of heat and pressure to the part material and support material such that a portion of the part material and support material flows into and at least partially fills the gap between the part material and support material.
A method for printing an article using a selective toner electrophotographic process, the method comprising:
The method of any of claims 1 and 3-13, wherein the first plane comprises the X-Y plane.
The method of any of claims 1-2 and 4-13, wherein at least a portion of the flow vector of the part material or support material within the gap includes a component outside of the first plane.
The method of any of claims 1-3 and 5-13, wherein the aggregate printed part material or support material of the edge enhancement layers have a volume substantially equal to the volume of the gap.
The method of any of claims 1-4 and 6-13, wherein an edge enhancement layer is deposited on average every second, third, fourth, fifth, sixth, seventh, eighth, ninth, or tenth layer.
The method of any of claims 1-5 and 7-13, wherein the edge enhancement layer has an average width of 5 to 15 pixels.
The method of any of claims 1-6 and 8-13, wherein the average width of the gap between the part regions and support regions is from 6 to 12 pixels.
The method of any of claims 1-7 and 9-13, wherein the gap is from 6 to 12 pixels in width and the average width of the edge enhancement layer is from 10 to 20 pixels in width.
The method of any of claims 1-8 and 10-13, wherein the average width of the gap between the part material and support material is from 5 to 25 pixels.
The method of any of claims 1-9 and 11-13, further comprising reheating, compressing, and recooling the build surface so as to cause the gap to diminish and the part region surface to become progressively smoother.
The method of any of claims 1-10 and 12-13, wherein the surface roughness of vertical part surfaces is less than 8 um.
The method of any of claims 1-11 and 13, wherein the surface roughness of vertical part surfaces is less than 4 um.
A method for printing an article using a selective toner electrophotographic process, the method comprising:
The method of any of claims 14 and 16-26, wherein at least a portion of the part material and/or support material flows upward in a Z-direction with a component normal to the X-Y plane within the gap.
The method of any of claims 14-15 and 17-26, wherein at least a portion of the part material or support material has a flow vector component outside of the X-Y plane.
The method of any of claims 14-16 and 18-26, wherein the aggregate part material or support material of the edge enhancement layers has a volume substantially equal to the volume of the gap.
The method of any of claims 14-17 and 19-26, wherein an edge enhancement layer is deposited on average every second, third, fourth, fifth, sixth, seventh, eighth, ninth, or tenth layer.
The method of any of claims 14-18 and 20-26, wherein the edge enhancement layer has an average width of 5 to 15 pixels.
The method of any of claims 14-19 and 21-26, wherein the average width of the gap between the part regions and support regions is from 6 to 12 pixels.
The method of any of claims 14-20 and 22-26, wherein the gap is from 6 to 12 pixels in width and the average width of the edge enhancement layer is from 10 to 20 pixels in width.
The method of any of claims 14-21 and 23-26, wherein the average width of the gap between the part material and support material is from 5 to 25 pixels.
The method of any of claims 14-22 and 24-26, further comprising reheating, compressing, and recooling the build surface so as to cause the gap to diminish and the part region surface to become progressively smoother.
The method of any of claims 14-23 and 25-26, wherein the surface roughness of vertical part surfaces is less than 8 um.
The method of any of claims 14-24 and 26, wherein the surface roughness of vertical part surfaces is less than 4 um.
A method for printing an article using a selective toner electrophotographic process, the method comprising:
The method of any of claims 27 and 29-35, further comprising deposit of an edge enhancement layer between at least some of the multiple layers of part material and support material;
The method of any of claims 27-28 and 30-35, wherein an edge enhancement layer is deposited every second, third, fourth, fifth, sixth, seventh, eighth, ninth, or tenth layer.
The method of any of claims 27-29 and 31-35, wherein the edge enhancement layer has an average width of 5 to 15 pixels.
The method of any of claims 27-30 and 32-35, wherein the average width of the gap between the part regions and support regions is from 6 to 12 pixels.
The method of any of claims 27-31 and 33-35, wherein the gap is from 8 to 12 pixels in width and the average width of the edge enhancement layer is from 10 to 20 pixels in width.
The method of any of claims 27-32 and 34-35, wherein the average width of the gap between the part material and support material is from 5 to 25 pixels.
The method of any of claims 27-33 and 35, further comprising reheating, recompressing, and recooling the build surface so as to cause the gap to diminish and the part region surface to become progressively smoother.
Dependencies are inferred from the claim text.